Oxy-hydrogen fuel integration and control system

ABSTRACT

An oxy-hydrogen generator control system may include an oxy-hydrogen generator for fuel production on demand. A controller may determine if ignition is present in a burner assembly prior to generating the oxy-hydrogen fuel and providing it to the burner assembly. The controller may also purge system lines of any residual oxy-hydrogen fuel when heating is no longer needed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims benefit under 35 U.S.C. §119(e) of U.S. Provisional Application having Ser. No. 61/472,978 filed Apr. 7, 2011, which is hereby incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention generally relates to fuel generation systems, and more particularly to an oxy-hydrogen fuel generation system.

Heating and hot water systems where people reside or work that rely on petroleum fuel can be cost prohibitive and waste fuel due to inefficient combustion. Inefficient combustion also produces higher levels of pollution.

Additionally, traditional storage of hydrogen alone involved keeping it as a liquid in a pressurized tank which can present dangerous conditions. For example, in storage tanks, there exists an ever present danger that the storage tank may explode.

As can be seen, there is a need for a safe fuel source that can be generated on demand. Additionally, there is a need for a fuel generator system that can be controlled to operate under safe conditions.

SUMMARY OF THE INVENTION

In one aspect of the present invention, an oxy-hydrogen generator control system comprises a burner assembly; an oxy-hydrogen generator coupled to the burner assembly; a valve coupled between the oxy-hydrogen generator and the burner assembly; and a controller coupled to the valve and the burner assembly, the controller configured to: detect a heat distribution source signal to initiate oxy-hydrogen fuel generation, detect a burner assembly signal that an ignition source is enabled, and provide a valve opening signal to the valve to allow oxy-hydrogen fuel into the burner assembly.

In another aspect of the present invention, an oxy-hydrogen generator control system comprises a burner assembly; an oxy-hydrogen generator coupled to the burner assembly; a valve coupled between the oxy-hydrogen generator and the burner assembly; and a controller coupled to the valve and the burner assembly, the controller configured to: detect a signal from a heat distribution source to initiate oxy-hydrogen fuel generation, detect a signal from the burner assembly that an ignition source is enabled, and provide a signal to the valve to allow oxy-hydrogen fuel into the burner assembly.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic diagram of an oxy-hydrogen generation control system according to an exemplary embodiment of the present invention;

FIG. 2 is top plan view of a burner assembly for use in the system of FIG. 1;

FIGS. 3A-3C are schematic illustrations of a valve and valve positions during use in the system of FIG. 1; and

FIG. 4 is a flowchart illustrating a series of steps according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention generally provides an oxy-hydrogen generation integration and control system. In one aspect, exemplary embodiments of the present invention may be useful in, for example, residential or commercial environments. Aspects of the present invention may supply an oxy-hydrogen fuel as an alternative heating source to petroleum based systems. Aspects of the present invention may generate oxy-hydrogen fuel on demand rather than storing a static supply of fuel. By contrast with heating systems that rely on petroleum fuel, oxy-hydrogen on demand generation uses water as the only fuel stored which presents no risk of combustion under any condition. Moreover, another aspect of the present invention provides a control system for enabling generation of oxy-hydrogen fuel under safety conditions.

Referring now to FIG. 1, a schematic of an oxy-hydrogen generation control system 100 (also referred to as the “system 100”) is shown in accordance with exemplary embodiments of the present invention. The system 100 may include a controller 110, a burner assembly 120, and an oxy-hydrogen generator 160. The system 100 may also include a manifold 130 between the burner assembly 120 and the oxy-hydrogen generator 160. A flashback arrestor 150 may be positioned between the manifold 130 and the oxy-hydrogen generator 160. A non-combustible air source 140 may be coupled to the manifold 130.

In one aspect, the controller 110 may be configured to control the production of oxy-hydrogen and the feed of oxy-hydrogen to the burner assembly 120 safely. For example, the controller 110 may be a programmable device, for example, a microprocessor including non-volatile memory incorporating instructions to operate elements of the system 100. It will be understood that lines emanating from the controller 100 to other elements in the system 100 may be electrical connections carrying signals.

In one exemplary embodiment, the controller 110 may be coupled to a thermostat 115. The thermostat 115 may be programmable to indicate to the controller 110 a threshold temperature that is needed at a heat distribution source (not shown), for example, a furnace or a hot water system. A switch 170, for example, a relay, may be coupled between the controller 110 and the oxy-hydrogen generator 160. When the thermostat is below the threshold temperature, the controller 110 may be configured to close the switch 170 so that a power supply (not shown) is delivered to the oxy-hydrogen generator 160. In one exemplary embodiment, the oxy-hydrogen generator 160 may be an electrolysis system carrying a water reserve that is converted into oxy-hydrogen fuel on demand rather than stored.

Referring now to FIGS. 1 and 2, the system 100 and an enlarged view of the burner assembly 120 is shown in accordance with an exemplary embodiment of the present invention. The burner assembly 120 may include a micro-nozzle 125 and a primary fuel ignition nozzle 126. The micro-nozzle 125 may be proximate the primary fuel ignition nozzle 126 so that fuel being expelled by the micro-nozzle 125 may be ignited by a lit primary fuel ignition nozzle 126. The micro-nozzle is utilized in this low pressure application to insure a positive exit pressure is maintained prohibiting any potential burn back and to insure the gas travels to the center of the primary flame pattern insuring even heat distribution. The controller 110 may be connected to the burner assembly 120 so that the ignition nozzle 126 may be enabled and ignited by igniters 123 by commands from the controller 110. An ignition thermal sensor 127 may be proximate the ignition nozzle 126. The controller 110 may be connected to the ignition thermal sensor 127 to determine based on feedback from the thermal sensor 127 that verifies the ignition nozzle 126 is indeed lit.

Referring now to FIGS. 1 and 3A-3C, the system 100 and various configurations of the manifold 130 are shown in accordance with exemplary embodiments of the present invention. The controller 110 may also be connected to the manifold 130. The manifold 130 may include an electrically activated pneumatic three position valve 135 allowing fluid to flow from the manifold 130 through conduit 175 to the micro-nozzle 125. The conduit 175 may include an internal volume insufficient to support combustibility within the line, for example, less than 200 mL. The controller 110 may control the position of the valve 135 between an oxy-hydrogen gas delivery mode, an air purge delivery mode, and a closed mode. FIG. 3A shows the oxy-hydrogen gas delivery mode where the valve 135 oxy-hydrogen gas to flow through section 131 to the burner assembly 120. FIG. 3B shows the air purge delivery mode where the valve 135 closes the section 131. Thus, the flow of oxy-hydrogen gas through to the burner assembly 125 is cutoff. Meanwhile, section 137 is opened, allowing non-combustible air from an air source 140 to flow into the conduit 175 and purging any residual oxy-hydrogen gas from the line to the burner assembly 120. The air source may be under low pressure, for example, less than 100 psi. FIG. 3C shows the closed mode where sections 131, 133, and 137 may all be partitioned from access to conduit 175.

Referring now to FIGS. 1 and 4, use of the system 100 through a series of steps of a method 400 are illustrated according to another exemplary embodiment of the present invention. In step 405, the system controller 110 may be activated. In step 410, the controller 110 may determine is power is available. If not, in step 415, the controller 110 may wait for power to be available or the system 100 may enter a shutdown mode. If power is available, in step 420 the system 100 enters a ready state. In step 425, the controller 110 may receive temperature level request from the thermostat 115 activating the controller 110 to supply heat to a heat distribution source. In step 430, the controller 110 activates the primary burner unit 120 control which initiates primary fuel ignition at the primary fuel ignition nozzle 126 and may check if the ignition nozzle 126 is indeed lit. If the controller 110 determines that the ignition nozzle 126 is not lit, then the controller 110 may activate an alarm until the nozzle 126 is lit or the system 100 is shutdown. If the nozzle 126 is indeed lit, then in step 440, the controller 110 may provide power to the oxy-hydrogen generator 160 to produce oxy-hydrogen gas and move the valve 135 into oxy-hydrogen gas delivery mode where the oxy-hydrogen fuel may be combusted in the burner assembly 120 and the resultant heat is delivered to the heat distribution source (not shown). In step 445, the controller 110 may receive an indication from the thermostat 115 that the temperature threshold is reached and additional heating is not needed. In step 450, the controller 110 may open the switch 170 and cut off power to the oxy-hydrogen generator 160. The controller 110 may also move the valve 135 into the air purge delivery mode for a predetermined time, for example 10 seconds and the valve 135 may then enter into the closed mode. In step 455, the controller 110 may wait until the thermostat 115 indicates the need for more heating or the system may then proceed into a shutdown in step 460.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

1. An oxy-hydrogen generator control system, comprising: a burner assembly; an oxy-hydrogen generator coupled to the burner assembly; a valve coupled between the oxy-hydrogen generator and the burner assembly; and a controller coupled to the valve and the burner assembly, the controller configured to: detect a heat distribution source signal to initiate oxy-hydrogen fuel generation, detect a burner assembly signal that an ignition source is enabled, and provide a valve opening signal to the valve to allow oxy-hydrogen fuel into the burner assembly.
 2. The oxy-hydrogen generator control system of claim 1 wherein the oxy-hydrogen generator is an electrolysis system.
 3. The oxy-hydrogen generator control system of claim 2 wherein the controller is configured to detect if electrical power is available to the electrolysis system.
 4. The oxy-hydrogen generator control system of claim 1 wherein the valve includes an oxy-hydrogen gas delivery mode, an air purge delivery mode, and a closed mode.
 5. The oxy-hydrogen generator control system of claim 4 wherein the controller is also configured to, during the purge delivery mode, purge a conduit leading to the burner assembly from the valve prior to closing the valve into the closed mode.
 6. The oxy-hydrogen generator control system of claim 1 wherein the burner assembly includes a micro-nozzle coupled to the valve and the ignition source is disposed proximate the micro-nozzle.
 7. An oxy-hydrogen generator control system, comprising: an oxy-hydrogen micro-nozzle burner; an oxy-hydrogen electrolysis generator coupled to the micro-nozzle burner; a water source coupled to the electrolysis generator; a conduit between the electrolysis generator and the micro-nozzle burner, the conduit having an internal volume of less than 200 ml; and a controller coupled to the valve and the burner assembly, the controller configured to: detect a signal that an ignition source proximate the micro-nozzle burner is enabled, and allow oxy-hydrogen fuel from the electrolysis generator into the micro-nozzle burner.
 8. The oxy-hydrogen generator control system of claim 7 further comprising a switch coupled between the controller and the electrolysis generator, wherein the controller is configured to close the switch and allow power to the electrolysis generator for producing oxy-hydrogen fuel.
 9. The oxy-hydrogen generator control system of claim 8 wherein the controller is configured to release a non-combustible air supply into the conduit purging oxy-hydrogen fuel from the conduit.
 10. The oxy-hydrogen generator control system of claim 8 further comprising a thermostat coupled to the controller wherein the controller is configured to open the switch when a threshold temperature is detected on the thermostat. 